CSF Racing Intercooler (07-13 335i, 08-13 135i)

Is it time to replace your OEM intercooler?

• The weak plastic endcaps can become weak & brittle over time with repeated heat cycle use and normal wear. Keep in mind the model range of 2004-2013 so the original OEM intercooler can be anywhere from 5 to almost 15 years old at the time of writing this article. 
• The OEM style tube/fin core has many performance limitations (keep reading below), and may also become full of debris from typical road use effecting performance of an already limited intercooler. Also, being mounted in the front fascia of the vehicle, small rock chips or debris may cause small punctures in the tubes of the core, causing small boost leaks which users may not realize, further reducing intercooler performance. 
• The direct injection system of the N54 engine causes massive amounts of oil build up in the charge piping, intercooler, and intake manifold. This further reduces the performance of the intercooler. 
• Before purchasing another OEM replacement intercooler for ~$530USD, potential buyers should realize that there is a much better alternative (at an even better price point!) with CSF’s new BMW N54 intercooler. 

Intercooler Design

• The OEM intercooler is made from plastic end tanks that are crimped on to an aluminum tube/fin core that is ~4 inches thick (105mm core width) and is 5 inches in height (127mm). This may be enough to keep IAT’s in check on a completely unmodified / stock vehicle, but once users to start increase power through bolt-on modifications, tuning, and built engines, the OEM intercooler will become the Achilles heel of the system with IAT’s skyrocketing out of the optimal range and drastically lowering the performance capabilities of the vehicle. 
• Enter CSF with their new, stepped core design, bar/plate high performance BMW n54 intercooler. This “drop-in fit” intercooler, which requires no modifications to install, has a bottom / larger section that is 5.5 inches thick (140mm) with a front face that is massive ~8.25 inches tall (210mm). A huge improvement over the OEM unit, and enough to handle even the most advanced n54 engine builds. Good for 1000hp no problem!

Core

• The OEM, and some higher-price aftermarket units, are made out of a tube/fin style core. While lightweight, this type of core is prone to heat soaking under high boost levels and prolonged use. Also, the core is susceptible to bursting (or bulging) due to increased boost levels as tube/fin cores can not take the higher boost pressures of a high performance system. 
• CSF’s new BMW N54 intercooler is made from it’s industry exclusive rounded bar/plate core design. The rounded front face of the cooling bars allows for better airflow into the core. Airflow hits the core surface, and rather than scattering like it does with hitting the face of a flat bar that all competing products have, it travels around the face of the round bar and into core for much better performance than both the OEM design (flat face) and all other aftermarket competitors (all have flat face tubes or bars).
• CSF has also wind-tunnel tested (in-house) and optimized the size of the core and fin density of the intercooler core to ensure low pressure drop and proper airflow into the rest of the system, including the radiator which is known to be another shortcoming of the cooling system. 

With CSF’s high performance bar/plate style core, you never have to worry about spikes in pressure or failure due to higher boost pressures, the CSF intercooler is pressure tested to 120psi!

Endtanks

• Compared to the OEM style plastic crimped on end tanks, the CSF unit is vastly improved. The all-aluminum cast end tanks are 100% TIG welded to the high performance core for better durability, reliability, and longevity. The CSF intercooler comes with a lifetime guarantee against manufacturing defects or failure due to normal / intended use. 
• Just like the OEM design, the CSF intercooler integrates the factory style “Quick-Connect” inlet/outlet fittings. CSF has CNC machined and welded these fittings to the core for perfect factory-level fitment. (new high performance locking spring clip included)